U.S. patent application number 12/775173 was filed with the patent office on 2011-11-10 for method and apparatus for operating a movable barrier.
This patent application is currently assigned to CHAMBERLAIN AUSTRALIA PTY. LTD.. Invention is credited to Scott J. Nicholson.
Application Number | 20110275476 12/775173 |
Document ID | / |
Family ID | 44902305 |
Filed Date | 2011-11-10 |
United States Patent
Application |
20110275476 |
Kind Code |
A1 |
Nicholson; Scott J. |
November 10, 2011 |
Method and Apparatus for Operating a Movable Barrier
Abstract
The movable barrier operator 10 is a shaft-mounted movable
barrier operator that operates a garage door 20. Such an operator
includes a motor 22 operably connected to shaft 26 such that motor
22 may move door 20 between the open and closed position. Shaft 26
may include axle 36 and wheels 38. The movable barrier 10 further
includes a rotational drive unit 46 with a sun gear 52 having an
open center 49 into which the axle 36 extends. Further, the
rotational drive unit may have an annularly shaped portion 47 and a
removable portion 48 such that the operator 10 may be installed
onto a previously mounted garage door. The movable barrier operator
may also include protection plates or a finger guard 90.
Inventors: |
Nicholson; Scott J.; (Green
Point, AU) |
Assignee: |
CHAMBERLAIN AUSTRALIA PTY.
LTD.
Lane Cove
AU
|
Family ID: |
44902305 |
Appl. No.: |
12/775173 |
Filed: |
May 6, 2010 |
Current U.S.
Class: |
475/331 ; 29/428;
74/606R |
Current CPC
Class: |
Y10T 29/49826 20150115;
E06B 9/70 20130101; E06B 9/174 20130101; Y10T 74/2186 20150115 |
Class at
Publication: |
475/331 ;
74/606.R; 29/428 |
International
Class: |
F16H 57/08 20060101
F16H057/08; B23P 11/00 20060101 B23P011/00; F16H 57/02 20060101
F16H057/02 |
Claims
1. A shaft-mounted operator configured to drive a movable barrier
between a first and a second position, the operator comprising: a
motor having a motor housing; a drive gear operably connected to
the motor; a sun gear engaging the drive gear along a circumference
of the sun gear, the sun gear being configured to couple with a
movable barrier to move the movable barrier between a first
position and a second position; at least one sun gear support; and
wherein the drive gear and the at least one sun gear support are
positioned off-set from a center of the sun gear and engage the
circumference of the sun gear and wherein the sun gear is not
supported by a central bearing.
2. The shaft-mounted operator of claim 1, wherein the at least one
sun gear support comprises a first sun gear support and a second
sun gear support positioned off-set from the center of the sun
gear.
3. The shaft-mounted operator of claim 1 wherein the at least one
sun gear support comprises a rotatable, idler gear.
4. The shaft-mounted operator of claim 1 wherein the at least one
sun gear support comprises an arcuate lip.
5. The shaft-mounted operator of claim 2 wherein the drive gear and
the first sun gear support engage an inner surface of the
circumference of the sun gear and the second sun gear support
engages an outer surface of the circumference of the sun gear.
6. The shaft-mounted operator of claim 1 wherein the sun gear
defines a substantially hollow center configured to receive a
portion of a support for the movable barrier.
7. The shaft-mounted operator of claim 1 wherein the sun gear
extends beyond the motor housing and comprises a first portion and
a second portion, the second portion being removable from the first
portion.
8. The shaft-mounted operator of claim 1 wherein the sun gear
extends beyond the motor housing, the shaft-mounted operator
further comprising a first protection plate and a second protection
plate, the first protection plate and the second protection plate
being pivotally connected to the motor housing wherein the first
and the second protection plates are pivotal between a first
position and a second position, the first position substantially
covering the portion of the sun gear extending beyond the motor
housing facing away from a movable barrier connection and the
second position exposing at least a portion of the sun gear
extending beyond the motor housing.
9. A shaft-mounted operator configured to be installed to operably
engage a previously installed movable barrier to drive the movable
barrier without removing the movable barrier, the shaft-mounted
operator comprising: a motor having a motor housing; and a sun gear
operably connected to and driven by the motor, wherein the sun gear
comprises a first portion and a removable second portion, wherein
the second portion is removable from the first portion allowing
assembly of the sun gear on the shaft without removal of the shaft
from its installation.
10. The shaft-mounted operator of claim 9 wherein assembly of the
sun gear includes assembling the first portion and the second
portion.
11. The shaft-mounted operator of claim 9 wherein the first portion
of the sun gear further includes an opening configured to receive
the removable second portion.
12. The shaft-mounted operator of claim 11 wherein the first
portion includes a first aperture and a second aperture, the first
aperture and the second aperture positioned proximate the opening
in the sun gear.
13. The shaft-shaft operator of claim 12, wherein the removable
second portion of the sun gear includes a body from which a first
leg and a second leg extend in one direction and arcuate flanges
extend in the opposite direction.
14. The shaft-shaft operator of claim 13 wherein the first leg of
the removable second portion is configured to extend through the
first aperture of the first portion and the second leg of the
removable second portion is configured to extend though the second
aperture of the first portion.
15. The shaft-mounted operator of claim 14 wherein the first and
second legs extending through the first and second apertures are
configured to engage an installed movable barrier, the first and
second legs being operable to move the installed movable barrier
from a first position to a second position.
16. The shaft-mounted operator of claim 9 wherein the removable
second portion is configured to operably engage the movable barrier
when engaging the first portion of the sun gear.
17. The shaft-mounted operator of claim 9 wherein the first portion
of the sun gear is configured to be slidably mounted on a
previously installed movable barrier without removing the movable
barrier and the removable second portion is connectable to the
first portion when the first portion is mounted on the previously
installed movable barrier.
18. The shaft-mounted operator of claim 9, the sun gear further
comprising gear teeth on an inner surface of the circumference of
the first portion and the removable section portion of the sun
gear.
19. The shaft-mounted operator of claim 9 wherein the sun gear is
incorporated into a rotational drive unit that further includes
strengthening ribs that the rotational drive unit.
20. The shaft-mounted operator of claim 9 further comprising a
first protection plate and a second protection plate, the first
protection plate and the second protection plate being connected to
the motor housing, wherein the first protection plate and the
second protection plate are movable between a first position and a
second position, wherein when in the first position the first
protection plate and the second protection plate substantially
cover a portion of the sun gear extending beyond the motor housing
facing away from a movable barrier connection and when in the
second position the first protection plate and the second
protection plate expose at least a portion of the sun gear
extending beyond the motor housing.
21. The shaft-mounted operator of claim 20 wherein when the first
and second protection plates are positioned in the second position
the removable second portion of the sun gear is removable from the
first portion between the first protection plate and the second
protection plate.
22. The shaft-mounted operator of claim 9 further comprising: a
drive gear operably connected to the motor; at least one sun gear
support disposed on the motor housing; and the sun gear engaging
the drive gear along a circumference of the sun gear; wherein the
drive gear and the at least one sun gear support are positioned
off-set from a center of the sun gear and engage the circumference
of the sun gear wherein the sun gear is not supported by a central
bearing, and wherein the sun gear is configured to couple to the
previously installed movable barrier to move the previously
installed movable barrier between the first and second
position.
23. An apparatus comprising: a motor having a motor housing; a sun
gear operably connected to and driven by the motor, wherein a
portion of the sun gear extends beyond the motor housing; at least
one protection plate connected to the motor housing, wherein the at
least one protection plate is movable between a first position and
a second position, the first position substantially covering at
least one side of the portion of the sun gear extending beyond the
motor housing and the second position exposing at least part of the
portion of the sun gear extending beyond the motor housing.
24. The apparatus of claim 23 wherein the second position of the at
least one protection plate is configured to permit removal of a
part of the sun gear configured to engage a previously installed
movable barrier.
25. The apparatus of claim 23, the sun gear further comprising an
annular shaped portion having an opening configured to receive a
removable sun gear portion, wherein to permit mounting of the sun
gear onto the previously installed movable barrier, the opening of
the sun gear is positioned to be exposed when the first and second
protection plates are in the second position.
26. The apparatus of claim 25 wherein the annular shaped portion
further comprises a first aperture and a second aperture positioned
adjacent the opening of the annular shaped portion and wherein when
the first and second protection plates are in the second position
the first and second apertures of the annular shaped portion of the
sun gear are exposed.
27. The apparatus of claim 23 further comprising: a drive gear that
drives the sun gear; a support gear that rotatably supports the sun
gear; and wherein the first and second plates have holes therein,
through which one of either the drive gear or the support gear
extend such that first and second plates are connected to the motor
housing at one of the drive gear and the support gear.
28. The apparatus of claim 23 further comprising a latch wherein a
first portion of the latch is associated with the first protection
plate and a second portion of the latch associated with the second
protection plate, the latch configured to the secure the first and
second protection plates to one another in the second position.
29. The apparatus of claim 23 further comprising an expandable
shaft coupling configured to fixedly connect the motor housing to a
hollow axle.
30. The apparatus of claim 29 wherein the sun gear defines an open
rotational center and wherein the expandable shaft coupling is
positioned at approximately the open rotational center of the sun
gear such that the hollow axle is positioned at the open rotational
center of the sun gear.
31. The apparatus of claim 29 wherein the expandable shaft coupling
comprises a center bolt and at least two wings wherein the at least
two wings are configured to expand when the center bold is
rotated.
32. A method of installing a shaft-mounted operator to a previously
installed movable barrier, the method comprising: providing a motor
having a motor housing, the motor operably coupled to a drive gear
configured to engage a sun gear associated therewith, and the motor
housing having at least one protection plate attached thereto, the
at least one protection plate configured to move between a first
position substantially covering a portion of the sun gear that
extends beyond the motor housing and a second position
substantially exposing the portion of the sun gear; arranging the
at least one protection plate into the second position
substantially exposing the portion of the sun gear, the sun gear
having an annular shaped body with an opening and an open center,
the opening of the annular body configured to receive a removable
sun gear portion; mounting the motor housing and the associated sun
gear with the removable sun gear portion removed; mating the
removable portion of the sun gear to the annular shaped body of the
sun gear, wherein the removable portion includes a first and a
second projections that extend through first and second apertures
in the annular shaped body of the sun gear, the first and second
projections are configured to engage the installed movable barrier;
and positioning the at least one protection plates in the first
position substantially covering the portion of the sun gear.
33. The method of claim 32 wherein mounting the motor housing
further comprises mounting the motor housing adjacent an end of the
installed movable barrier wherein a barrier axle of the movable
barrier extends into the open center of the sun gear.
34. A jackshaft operator configured to be installed to drive a
barrier between a first and a second position without uninstalling
the barrier, the jackshaft operator comprising: a motor having a
motor housing; a drive gear operably connected to the motor; a sun
gear engaging the drive gear along a circumference of the sun gear,
the sun gear being configured to operably couple to a movable
barrier via a sun gear removable portion to move the movable
barrier between a first and a second position, wherein a portion of
the sun gear extends beyond the motor housing to permit removal of
the sun gear removable portion; at least one sun gear support
mounted on the motor housing, wherein the drive gear and the at
least one support gear are positioned off-set from a center of the
sun gear and engage the circumference of the sun gear; at least one
protection plate configured to connect to the motor housing wherein
the at least one protection plate is movable between a first
position and a second position, wherein when in the first position
the at least one protection plate substantially covers a side of
the portion of the sun gear extending beyond the motor housing and
when in the second position the at least one protection plate
exposes at least part of the portion of the sun gear extending
beyond the motor housing.
35. The jackshaft operator of claim 34 further comprising a support
panel fixedly attached to the motor housing, the support panel
having a bore therethrough and a coupler having a center bolt
configured to extend through the bore in the support panel and into
a center of the coupler to secure the motor housing to the
coupler.
36. The jackshaft operator 34 further comprising a coupler
configured to fixedly connect the motor housing to a hollow axle,
wherein the coupler is configured to expand to contact an inside
surface of the hollow axle.
37. The jackshaft operator of claim 36 wherein the coupler further
comprises at least two wings configured to expand outwardly when
the bolt in the coupler is rotated.
38. The jackshaft operator of claim 37 wherein the coupler is
attached to the support plate such that the coupler is positioned
at substantially a center of the sun gear.
Description
TECHNICAL FIELD
[0001] This invention relates generally to barrier movement
operator and more specifically to the installation of an operator
onto a previously installed movable barrier.
BACKGROUND
[0002] Barrier movement operators generally comprise power and
control systems for responding to operator inputs and sensed
conditions. Operators thereby move barriers, such as garage doors
or sliding gates, between open and closed positions. Various
systems for operating and controlling movable barriers have been
employed.
[0003] Though many movable barriers are now installed with
operating systems, previously installed systems may be retrofitted
to incorporate an operating and control system onto a movable
barrier. In addition, if an installed barrier operator has failed,
a new operating system may need to be incorporated onto a
previously installed movable barrier. In general, such systems
include a primary barrier control mechanism that couples with a
corresponding barrier and causes the barrier to move (typically
between closed and opened positions). One known approach to
installing an operator includes removing the previously installed
barrier or garage door from its mount and then install the operator
that is mated to the barrier prior to remounting. Many conventional
operators employ a sun gear with a central bearing that is
configured to mount onto an end of an axle or shaft in either of
what is known in the art as a live shaft or dead shaft
configuration. In such configurations, the operator extends below
the axle to accommodate a sun gear that rotates around the axle.
Further, installation of such a movable barrier operator typically
requires that the garage door be uninstalled so that the central
bearing of the sun gear may be mounted onto the axle without
interference from a bracket or other mounting structure. This, of
course, can be cumbersome, error prone, and time consuming to
accomplish, especially considering the size, weight, and shape of
many movable barriers. Alternatively, some installers disconnect a
portion of the barrier to avoid removing the entire mounted movable
barrier from its mounted position. To that end, an installer may
release one side of a mounted barrier, and may then rotate the
barrier off a single side to partially remove a previously
installed movable barrier. Such rotation and movement, however, may
be dangerous due to the weight of the door and may also require
specialized equipment.
[0004] In practice, though, some garage doors have been installed
into spaces with little additional room to accommodate conventional
operators. In such circumstances, even removing the movable barrier
from the door mount may not permit an operator and controller to be
installed into an insufficient space. Further, such space
restrictions can, in fact, limit the use of operators for newly
designed garage doors and openings where space is limited.
[0005] Conventional garage door operators such as rack and pinion
drives or push-pull drive chain types are suitable for use in
larger garage spaces which allow for hanger brackets to be
connected from the ceiling to provide a rail for a drive chain that
is connected to a trolley, which is movable along the rail.
However, many garages, such as older garages, have relatively low
ceilings and relatively little additional space to accommodate such
conventional operators. In such circumstances, a shaft-mounted
operator or jackshaft operator is often used to operate movement of
the barrier. Jackshaft operators are suitable for use with garages
having low ceilings or other space limitations as they do not
require the additional center rail and trolley. One example of a
jackshaft operation is described in U.S. Pat. No. RE40,001, which
is incorporated by reference as through fully rewritten herein. A
jackshaft operator typically has a motor with a motor housing and a
control unit. The motor is operably connected to a jackshaft that
is positioned parallel to an upper edge of the door and rotatably
mounted above the garage door frame. A torsion spring may be wound
around the jack shaft to provide a restoring force to it.
[0006] The jackshaft operator is typically mounted inside a parking
structure or garage on a wall thereof immediately above the door
opening and slightly offset, near a corner edge thereof. The
jackshaft operator is operably connected to the jack shaft, which
comprises a portion of the garage door structure and has a
torque-providing helical spring wound thereabout for providing a
restoring torque to the jackshaft. While such jackshaft operators
occupy minimal space compared to operators having a rail and
trolley configuration, some jackshaft operators still employs
L-shaped tracks into which rollers attached to the garage door are
permitted to ride, thereby guiding movement of the barrier from the
open to closed position. The tracks may require additional
installation and can be difficult for very small spaces to
accommodate.
[0007] In addition, installing such an operator to a previously
mounted garage door, as mentioned, can be quite difficult,
especially considering the weight of a typical garage doors and
barriers. For example, some operator configurations require that
the previously mounted garage door be dismounted so that the
operator can be positioned and properly mated with the garage door.
Further, some garage doors have low ceilings and little additional
room for a movable barrier operator that is significantly offset
from the opening. For example, in a garage where the wall
surrounding the opening adjoins another wall near that opening such
that the space between the opening and the adjoining wall is
limited.
SUMMARY
[0008] Generally speaking, and pursuant to these various
embodiments, an operator, as described herein, includes a motor
with a motor housing and drive gear. Further, it is contemplated
that the operator includes a rotational drive unit with a sun gear
that engages the drive gear along a circumference of the sun gear.
In one approach, the drive gear and the sun gear support are
positioned off-set from the rotational center of the sun gear and
engage the circumference of the sun gear such that neither the sun
gear nor the rotational drive unit is supported by a central
bearing at its rotational axis. In one approach, the sun gear is
configured to couple with a movable barrier to move the barrier
between the first and second position. In one aspect, the apparatus
may be configured to couple to a movable barrier in one of a
live-shaft configuration or a dead-shaft configuration. In another
one aspect, the sun gear support includes several bearings such as
first and second gear supports positioned off-set from the center
of the sun gear. In still another aspect, the sun gear support
includes an arcuate lip or another gear.
[0009] In another approach, a shaft-mounted operator includes a
motor, motor housing, and sun gear driven by the motor, where the
sun gear has a removable portion allowing assembly of the sun gear
onto the shaft without removal of the shaft and garage door from
their installed position. An annular, first portion of the sun gear
includes openings that are configured to receive portions of a
second, removable portion thereby mating the removable portion of
the sun gear with the annular portion of the sun gear. Further, the
sun gear is configured to be slidably mounted onto a previously
installed movable barrier without removing the movable barrier. In
addition, once the annular portion of the sun gear and associated
motor housing have been connected to the shaft, the removable
portion of the sun gear may be connected to the remainder of the
sun gear.
[0010] So configured, a conveniently mountable movable barrier
operator may be mounted into less than ideals locations, such as a
confined space that would typically not accommodate a conventional
movable barrier operator. Such a mountable movable barrier operator
would be conveniently mountable proximate the shaft and is smaller
to thereby accommodate a variety of installation configurations and
save costs. Further, such a conveniently mountable operator is
lighter and, therefore, easier to install. One such movable barrier
operator, such as a shaft-mounted operator, then may be installed
onto a previously installed movable barrier without requiring
removal of a previously installed barrier from its mount.
[0011] In one configuration, a portion of the sun gear extends
beyond the motor housing. The In one such approach, a protection
mechanism, such as protection plate(s), is connected to the motor
housing between the housing and the sun gear. The plate(s) being
movable between two positions where one of the positions
substantially covers the portion of the sun gear that extends
beyond the motor housing and another position that exposes a
portion of the sun gear that extends beyond the motor housing. The
plate position exposing a portion of the sun gear that extends
below the housing is used when the removable portion of the sun
gear is mated with the annular portion of the sun gear.
[0012] So configured, a movable barrier operator may include a
protection mechanism, such as a finger guard, that does not require
removal of the protection mechanism for assembly or installation of
the operator.
[0013] In one approach, a method of installing an operator onto a
previously installed movable barrier includes providing a motor, a
motor housing, a drive gear, an associated sun gear, and a
protection plate. The method further includes arranging the
protection plate into a position substantially exposing the portion
of the sun gear extending beyond the motor housing. The sun gear
having an annular shaped body with an opening and an open center,
the opening of the annular body configured to receive a removable
sun gear portion. The method also includes mounting the motor
housing and associated sun gear to a shaft supporting a garage
door, while the removable portion of the sun gear is removed. Once
the operator is positioned adjacent the shaft, the removable
portion of the sun gear is mated to the annularly shaped body of
the sun gear. The removable portion may have a first projection and
a second projection that may extend through first and second
apertures in the annular shaped body of the sun gear where the
first and second projections are configured to engage a portion of
the installed movable barrier. The method of installation also
includes positioning the protection plate in a position
substantially covering the portion of the sun gear that extends
beyond the motor housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The above needs are at least partially met through provision
of the method and apparatus described in the following detailed
description, particularly when studied in conjunction with the
drawings, wherein:
[0015] FIG. 1 comprises a perspective view of an inside of a garage
with a movable barrier and operator as configured in accordance
with various embodiments of the invention;
[0016] FIG. 2 comprises an enlarged perspective view of a portion
of an inside of a garage with a movable barrier and operator as
configured in accordance with various embodiments of the
invention;
[0017] FIG. 3 comprises a schematic cross section of a portion of
the movable barrier as configured in various embodiments of the
invention;
[0018] FIG. 4 comprises a perspective view of a movable barrier
operator with a portion of a sun gear removed as configured in
accordance with various embodiments of the invention;
[0019] FIG. 5 comprises a back view of the movable barrier operator
of FIG. 4 having protection plates in a position exposing a portion
of the sun gear, as configured in accordance with various
embodiments of the invention;
[0020] FIG. 6 comprises a back view of the movable barrier operator
of FIG. 5 having protection plates in a position covering a portion
of the sun gear, as configured in accordance with various
embodiments of the invention;
[0021] FIG. 7 comprises a back view of a movable barrier operator
with an alternative protection plate and having a portion of the
associated gear removed, as configured in accordance with various
embodiments of the invention;
[0022] FIG. 8 comprises a bottom view of the movable barrier
operator of FIG. 4 as configured in accordance with various
embodiments of the invention;
[0023] FIG. 9 comprises a front view of the movable barrier
operator of FIG. 4 as configured in accordance with various
embodiments of the invention;
[0024] FIG. 10 comprises a top view of the movable barrier operator
of FIG. 4 as configured in accordance with various embodiments of
the invention;
[0025] FIG. 11 comprises a perspective view of the movable barrier
of FIG. 4 having the removable portion of the sun gear mated
therewith, as configured in accordance with various embodiments of
the invention;
[0026] FIG. 12 comprises a side view of the movable barrier of FIG.
4 having the removable portion of the sun gear removed therefrom,
as configured in accordance with various embodiments of the
invention;
[0027] FIG. 13 comprises a side view of the movable barrier of FIG.
4 having the removable portion of the sun gear mated therewith, as
configured in accordance with various embodiments of the
invention;
[0028] FIG. 14 comprises a perspective view of a portion of a
movable barrier operator having the sun gear removed as configured
in accordance with various embodiments of the invention;
[0029] FIG. 15 comprises a perspective view of an alternative
configuration of a movable barrier operator, as configured in
accordance with various embodiments of the invention;
[0030] FIG. 16 comprises a perspective view of an alternative
configuration of a movable barrier operator, as configured in
accordance with various embodiments of the invention;
[0031] FIG. 17 comprises a block diagram of a method of
installation, as configured in accordance with various embodiments
of the invention;
[0032] FIG. 18 comprises a bottom perspective view of a movable
barrier operator with an expandable coupler, as configured with
various embodiments of the invention.
[0033] Skilled artisans will appreciate that elements in the
figures are illustrated for simplicity and clarity and have not
necessarily been drawn to scale. For example, the dimensions and/or
relative positioning of some of the elements in the figures may be
exaggerated relative to other elements to help to improve
understanding of various embodiments. Also, common but
well-understood elements that are useful or necessary in a
commercially feasible embodiment are often not depicted to
facilitate a less obstructed view of these various embodiments. It
will further be appreciated that certain actions and/or steps may
be described or depicted in a particular order of occurrence while
those skilled in the art will understand that such specificity with
respect to sequence is not actually required. It will also be
understood that the terms and expressions used herein have the
ordinary technical meaning as is accorded to such terms and
expressions by persons skilled in the technical field as set forth
above except where different specific meanings have otherwise been
set forth herein.
DETAILED DESCRIPTION
[0034] Referring now to the drawings, and in particular to FIGS.
1-3, a movable barrier operator is shown therein denoted as
reference 10. The movable barrier operator 10, as illustrated, is a
shaft-mounted movable barrier operator that is mounted inside a
parking structure or garage 12 on a wall 14 immediately above the
opening 16, which is closed by a barrier or garage door 20. The
movable barrier operator 10 includes a motor 22 inside motor
housing 24, the motor 22 being operably connected to a shaft 26
such that the motor 22 may move the door 20 between the open and
closed position. The shaft 26 may extend across and just above the
garage opening 16. The garage door 20 is supported by the shaft 26,
which is supported at the ends by a door mount such as a bracket
30. As used herein, a shaft-mounted movable barrier operator is one
that is mounted proximate the shaft, such as those mounted onto the
axle, the bracket supporting the shaft, or through another mounting
configuration. Further, the shaft 26 may include an axle 36 and
wheels 38 mounted thereto.
[0035] As illustrated in FIG. 1, the barrier may be a multi-panel
garage door or barrier curtain 20. By one approach, the multi-panel
garage door 20 includes long rectangular door panels or slats 28
that are hingedly attached to one another. The garage door 20 is
supported in part by the shaft 26, portions of which may be
rotatable and portions of which may be fixed. In one example
discussed below, the shaft 26 is comprised of an axle 36 and at
least two wheels 38. Further, in one illustrative embodiment, the
axle 36 has two wheels 38 mounted thereon, one located proximate
each end of the axle 36. Such an embodiment, as installed, permits
the wheels 38 to rotate around the axle 36, thereby winding the
door therearound. Further, by one approach, the multi-panel garage
door 20 is a roll type door, similar to a roller shade for home
windows, such that at least some of the slats 28 will wrap around
shaft 26 when the door 20 is raised and the garage opening 16 is
exposed. In one illustrative embodiment, the garage door 20 is
fixedly connected to the wheels 38 such that when the wheels 38 are
rotated by the movable barrier operator 10, slats 28 are wrapped
therearound. Further, the garage door 20 may be any type of movable
barrier, such as a rolling window shade, window protector, or an
awning, in addition to a garage door. An enlarged perspective
illustrated in FIG. 2, shows the movable barrier operator 10
proximate a side of the garage door 20 and opening 16. Further, the
garage door 20, via the shaft 26, is supported by a bracket 44,
which is positioned above the opening 16. In one illustrative
approach, a door, such as a metal door, may have insulation
attached thereto. Alternatively, the door may be comprised solely
of metal. A variety of metals may be used to construct the door.
Materials for the motor housing may include any of a variety of
metals or hard plastics. In addition, the brackets, axles, and
wheels are also generally comprised of any of a variety of
metals.
[0036] In one example illustration shown in FIG. 3, the shaft 26 is
schematically shown at the side of opening 16. Further, the shaft
26 includes an axle 36 (which extends along the length of and just
above the opening 16) and a wheel 38 mounted thereto, though other
configurations are contemplated. Further, by one approach, the
wheel 38 has three spokes 40. By another approach, the wheel 38 may
have more or fewer spokes or, alternatively, may be disk-like and
have no spokes. The garage door 20 is connected to a portion of the
circumference of the wheel 38. By one approach, a few of the
uppermost panels or slats 28 are secured to the wheel 38 by
fasteners 39. Thus, when the wheel 38 is rotated, the door 20 will
wind or unwind around the wheel 38 and the axle 36 thereby raising
or lowering the garage door 20. By one approach, the wheel 38 has a
bearing incorporated therein, such as a roller bearing, to further
facilitate movement of the wheel 38 relative to the axle 36. In yet
another approach, the axle 36 may incorporate a bearing, such as a
roller bearing, to further facilitate movement of the wheel 38.
Tracks 42 may be included to act as guides for the ends of the
garage door 20.
[0037] As installed, one of the at least two wheels 38 is
positioned proximate an end of the axle that is adjacent the
operator 10. As mentioned, the garage door 20 may be raised or
lowered by rotation of wheel 38 because the door 20 is fixedly
attached to the wheel 38 by the fasteners 39. To that end, a
portion of the operator 10 engages with spokes 40 of the wheel 38
to rotate the wheel 38 and thereby move the garage door 20. When
the wheel 38 is rotated, the garage door 20, which is secured to
the wheel 38, is wound or unwound around the wheel 38 and the axle
36. As the door 20 is further wound around the wheel 38, a
drum-like structure is formed having the axle 36 at its center,
garage door slats 28 along the circumference of the drum-like
structure, and the wheels 38 at the ends. In addition, a torsion
spring may be wrapped around the axle in between the two wheels
38.
[0038] In one configuration illustrated in FIG. 1, the shaft 26
including the axle 36 and wheels 38 are contained within a shell 34
such that as the door 20 is raised, the slats 28 are wound around
shaft 26 and are pulled into the shell 34. The shell 34, like the
shaft 26, is positioned above the opening 16 of the garage 12. In
another configuration illustrated in FIG. 2, the garage door 20 may
be wound around the shaft 26 where the shaft 26 is not housed
within a shell. At the sides of the opening 16, the tracks 42 are
positioned such that the ends of the slats 28 are positioned
therein. As the door 20 is raised and lowered, the ends of the
slats 28 ride within the tracks 42 such that movement of door 20 is
guided by the tracks.
[0039] As mentioned, garage door 20 may be raised and lowered by
movable barrier operator 10. Operators for such roll-type doors are
generally attached to a point of reference, such as the axle 36 or
the bracket 30, while being positioned to engage the wheel 38. In
one approach, operator 10 is mounted onto axel 36 such that a
portion of operator 10 engages the spokes of wheel 38, thereby
rotating the wheel about the stationary axle.
[0040] FIGS. 1 and 2 illustrate one example of the movable barrier
operator 10 having a support panel or housing bracket 60, which
connects to an expandable shaft coupling 62 (FIG. 8). In one
illustrative approach, the support panel 60 extends from inside the
housing 24, where it can be secured to the remainder of operator 10
in a variety of manners. The expandable shaft coupling 62,
illustrated in FIGS. 8 and 18, fixedly attaches the operator 10 to
the axle 36 by engaging the inside surface of the axle. By one
approach, the expandable shaft coupling 62 is comprised of a fairly
hard metal that secures the operator 10 to the axle 36. The
expandable shaft coupling 62 is configured to be positioned within
the end of the hollow axle 36, and when a bolt 64 therein is
turned, the expandable shaft coupling 62 expands outward. By one
approach, the expandable shaft coupling 62 has wings 65, and when
the bolt 64 is rotated the wings 65 may expand outward to grip or
dig into the interior surface of the axle 36. In one example, the
wings 65 will dig into the interior surface of the axle 36 such
that small indentations are made in the surface to help hold the
expandable coupled 62 and the operator 10 in position.
[0041] As mentioned, the expandable shaft coupling 62 is configured
to expand when adjusted to clamp the movable barrier operator 10 to
axle 36 by the shaft coupling 62 clamping to the inside of the
hollow axle 36. Further, the expandable shaft coupling 62 may be
used for either dead shaft configurations (bearings are located on
the wheels that rotate) or live shaft configurations (bearings are
mounted on the axle), whereas many previous couplers mountable to
the outside of the axle were only mountable on dead shaft
configurations so that the coupler would not interfere with
bearings mounted on the axle. The expandable shaft coupling 62 is
fixedly attached to the support 60 by a bolt 64 that extends
through the panel 60 to the coupling 62. Conventional couplers that
clamped onto the exterior of the axle are also generally bigger
than the axle to grip the outside surface of the axle. In addition,
conventional couplers sometimes required that the shell 34 be
adjusted so as to provide access to the axle 36. By having the
expandable shaft coupling 62 engage the interior of the hollow
axle, the coupling between the motor and shaft is smaller and
lighter, and therefore, less expensive than would otherwise be
necessary and generally does not require shell adjustment when
accessing the axle. An expandable shaft coupling 62 generally
provides for easier installation and reinstallation, such as when
the door or motor are removed for maintenance, because in certain
spaces there is limited space for maneuvering hands and tools.
[0042] As installed, the movable barrier operator 10 may be
positioned primarily above the axle 36 such that the support 60
extends adjacent and slightly below an end of the axle 36 as shown
in FIGS. 1 and 2. As mentioned, the bolt 64 extends through the
support 60 to the axle 36 thereby securing the movable barrier
operator 10 to the axle. By one approach, having the movable
barrier operator 10 with an open center 45 permits the housing 24
to be mounted primarily above the axle and does not require the
housing of the operator to extend significantly past the end of the
axle 26 or significantly below the axle 36. In this example, by not
having a central bearing in the sun gear attached to the motor
housing, the operator housing does not extend significantly below
the axle.
[0043] Turning now to FIG. 4, a side of the example movable barrier
operator 10 is illustrated that faces the wheel 38 and is the side
opposite that illustrated in FIGS. 1 and 2. The movable barrier
operator 10, as shown, includes a rotational drive unit 46 with an
open center 45 through which the axle 36 may pass. The rotational
drive unit 46 also has an annularly shaped portion 47 and a
removable portion 48 illustrated having projections 54. By one
approach, the rotational drive unit 46 may be constructed of a
hardened plastic. By yet, another approach, the rotational drive
unit 46 may be constructed of a sintered or molded metal. The
rotational drive unit 46 is rotated by the motor 22 housed inside
motor housing 24. To this end, the rotational drive unit 46
includes the sun gear 52 that is disposed on both the
annularly-shaped first portion 47 and the removable second portion
48. The rotational drive unit 46 is operably attached to the motor
housing 24 through several supports positioned off-center from the
rotational axis of the drive unit. As mentioned above, a central
bearing is not employed to mount the rotational drive unit 46. The
off-center supports, illustrated in FIGS. 14-16, may be arranged in
a number of configurations. The first portion 47, which is
annularly-shaped, has an open center 45 and an opening 49. The
opening 49 is configured to receive the second removable portion 48
and, likewise, the second removable portion 48 is configured to
mate with first portion 47 at the opening 49 to thereby complete
the circular path of the circumference of the rotational drive unit
46, as illustrated in FIG. 9. In addition, the rotational drive
unit 46 also includes strengthening ribs 102 that permit the
rotational drive unit 46 to be reinforced without unduly increasing
the weight of the rotational drive unit 46 and the associated sun
gear 52.
[0044] More specifically, and with continuing reference to FIGS. 4
and 5, the annularly-shaped first portion 47 includes two apertures
53 adjacent the opening 49. Portions of removable portion 48 are
extendable through apertures 53 and portions mate with the opening
49. The first and second apertures 53 are disposed proximate
opening 49 on either side thereof. The removable portion 48
includes projections 54 that are extendable through apertures 53 in
the first portion 47 of the rotational drive unit 46. Further, a
first projection 54a is configured to extend through a first
aperture 53a and a second projection 54b is configured to extend
through a second aperture 53b. FIGS. 8 and 10-11 illustrate the
removable portion 48 mated with the first portion 47 to complete
the removable drive unit 46. As the removable portion 48 is mated
with the first portion 47, projections 54 extend through apertures
53 and into engagement with the spokes 40 of the wheel 38 when
installed. Further, the projections 54 are operable to move the
installed movable barrier from a first position to a second
position as they are rotated. Thus, such a mated configuration of
the portions of the rotation drive unit 46 is employed during
operation of movable barrier operator 10.
[0045] The annularly-shaped first portion 47 includes two sidewalls
58 and 59 and a plate 61 that is configured to join the two
sidewalls together proximate a side of the rotational drive unit 46
that faces the wheel 38. The sidewalls 58 and 59 follow a circular
path wherein the outer sidewall 58 has a larger circumference,
while the inner sidewall 59 has a smaller circumference. The
apertures 53 extend through plate 61 in between the two sidewalls
58, 59.
[0046] The removable portion 48 also includes a center plate 55
that is curved in shape to follow the opening 49 in the annular
shape of rotational drive unit 46. The removable portion 48
includes a flange 56 that is arcuate in shape to follow a side wall
58 of the annularly shaped rotational drive unit 46. The flange 56
aligns with the side wall 58 when the removable portion 48 is mated
with the first portion 47. The flange 56 extends from the plate 55
in a direction opposite the projections 54. The flange 56 and the
plate 55 may have portions of the sun gear 52 disposed thereon, as
discussed below. Further, the removable portion 48 also includes
wall portion 57 that aligns with the inner side wall 59 of the
rotational drive unit 46 when the removable portion 48 is mated
with the first portion 47.
[0047] When the removable portion 48 has been mated with the
remainder of the rotational drive unit 46, the projections 54 of
the removable portion 48 engage portions of the wheel 38. More
specifically, the projections 54 engage one of the spokes 40 of the
wheel 38. Further, a single spoke 40 is typically captured in
between the projections 54a, 54b such that one of the projections
extends along each side of the spoke.
[0048] The rotational drive unit 46 has a first side 43 that, when
installed, faces the wheel 38 and is illustrated in FIG. 4. A
second side 50 is opposite the first side 43, and the second side
50 faces the motor housing 24. A portion of second side 50 is
illustrated in FIG. 5 where the finger guard 90 is moved to expose
a portion of the sun gear 52 that is disposed on the side 50 of
rotational drive unit 46 and that extends beyond the motor housing
24. Once the removable portion 48 has been mated with the first
portion 47, the rotational drive unit 46 may be rotated by the
motor 22 in the housing 24. Such rotation occurs through a driving
gear operably connected to the motor 22 that engages the sun gear
52 disposed on the rotational drive unit 46. The sun gear 52,
including its gear teeth, is disposed upon both the removable
portion 48 and the first portion 47 of the rotational drive unit
46. More particularly, when the removable portion 48 is mated with
the annular portion 47, the gear teeth of the sun gear 52 align
such that the rotational drive unit 46 may be rotated by a driving
gear as if the removable portion 48 were formed as a single,
unitary rotatable gear unit with the first portion 47. The motor 22
engages gear teeth of the sun gear 52 by a drive mechanism such as
a pinion gear assembly. By one approach the gear teeth of the sun
gear 52 are primarily disposed on the interior surface of sidewall
58 of the rotational drive unit 46. As the motor 22 rotates a
pinion gear assembly, the rotational drive unit 46 is rotated along
with the projections 54. The projections 54 rotate the wheel 38 by
engaging one of the spokes 40 of the wheel. In one embodiment, a
release mechanism may be configured to permit the user to decouple
the pinion and the motor 22 such that the pinion is no longer
engaged and the door can be operated independent of the
operator.
[0049] In one approach, the wheels 38 are free to rotate about the
axle 36 that is constrained from rotation via bearings incorporated
into the wheel 38. By another approach, the axle being constrained
from rotation has bearings mounted thereon such that the wheels 38
are free to rotate around by engaging the bearings mounted on the
axle 36. Either configuration may permit rotation of the wheels 38
around the axle 36. Further, as the wheels 38 rotate, the door 20
is wound around the wheels 38 and axel 36. As mentioned above, the
movable barrier operator 10 rotates the wheels 38 to raise or lower
the garage door and such operators have typically required removal
of the door from its mount in order to install the operator. The
movable barrier operator 10, however, includes a removable portion
48 that permits installation of the operator 10 onto the axle 36
without removal of the door 30 and shaft 26 from the mounting
brackets 44. Indeed, the removable portion 48 permits the
rotational drive unit 46 to be mounted to engage the wheel 38 as it
rotates around the axle 36.
[0050] As installed, the projections 54 of the rotational drive
unit 46 will rotate around the axle 36, along with the wheel 38.
Thus, the axle 36 may extend into the open center 45 of the
rotational drive unit 46 such that the projections 54 rotate around
the axle 36 positioned in the open center of the rotational drive
unit 46. Indeed, it is anticipated that in many configurations the
axle 38 will extend into the open center 45 to engage the
expandable shaft coupling 62 with the axle 36 and to position the
projections 54 to contact the wheel 38. As the projections 54
rotate around the axle 36, the projections contact spokes 40 such
that the wheel 38 is rotated and the door is wound or unwound
around the shaft 26.
[0051] Installing movable barrier operators may be accomplished in
a number of manners. For example, the movable barrier operator 10
may be installed at the same time as the garage door 20, which
permits the installer to mount the operator on the axle at the same
time as the door is installed. Alternatively, while conventional
operators required the user to remove a mounted barrier in order to
permit the operator to be properly coupled to the barrier, the
movable barrier operator 10 may be mounted to a previously
installed door without requiring removal of the door. To that end,
the movable barrier operator 10 is configured to be mounted onto a
previously installed movable barrier by having the removable
portion 48 removed therefrom. Thus, the opening 49 in the first
portion 47 of the rotational drive unit 46 permits the axle 36 to
be positioned within the center opening 45 such that the rotational
drive unit 46 is proximate the wheel 38. The operator 10 is slid
onto the axle 36 via the opening 49, after which the coupling 62
may secure the operator 10 to the axle 36. Further, once the
movable barrier operator 10 is positioned adjacent the wheel and
axle end, the removable portion 48 may be mated with the opening
49, the apertures 53, and the wheel 38. In one illustrative
embodiment, the expandable coupling 62 may be mated to the axle 36
prior to mating the removable portion 48 with the remainder of
drive unit 46. Alternatively, in some configurations the removable
portion 48 may be mated with rotational drive unit 46 prior to
securing the expandable coupling 62 to the axle 36.
[0052] Turning now to FIGS. 14-16, several support configurations
for the rotational drive unit 46 are illustrated. While
conventional operators have a central bearing associated with the
sun gear, the three-point support for a sun gear described herein
removes the need for such a central bearing, thereby opening up the
potential size and shape of the operator. Further, by removing the
central bearing, the operator housing does not need to extend
significantly below the center line of the sun gear and the size of
the operator may be smaller. Further, possible shapes for the
operator are increased because they are not as constrained by the
requirement to support the central bearing. To this end, the
rotational drive unit 46, including the sun gear 52, is supported
by three points of engagement with the housing 24 via the bearing
assembly 66, 67, and 68. A variety of points of engagement or
bearings are contemplated such as gears (both pinion and idlers
gears) and plain bearings such as an arcuate surface configured to
permit rotation of the rotational drive unit, to note but a few
bearings.
[0053] By one approach, examples of which are shown in FIGS. 14-16,
two of the bearings are located on the interior of the rotational
drive unit 46, thereby engaging the sun gear 52. In such a
configuration, a third bearing engages an outer surface of the
rotational drive unit 46. The bearing engaging the outer surface of
the rotational drive unit 46 may engage either the sidewall 58 or
59. By another approach, two bearings are positioned to engage an
outer surface of the rotation drive unit 46, while a third bearing
engages an interior surface of the rotational drive unit 46. In
both configurations, at least one pinion gear is positioned to
engage an inside surface of the rotational drive unit 46 having sun
gear 52 disposed thereon. Alternatively, three gears may be used to
engage the interior of the rotational drive unit 46 such that two
of the gears engage one of the sidewalls and the other of the three
gears engages the other of the sidewalls. In yet another approach,
the bearing assembly may have one gear engaging the inside surface
of the rotational drive unit and two gears engaging the outer
surface of the drive unit.
[0054] As mentioned, the rotational drive unit 46 is driven by a
pinion gear that engages the sun gear 52 on the side 50 of the
drive unit 46. One such three-point support configuration, shown in
FIG. 14, includes a bearing assembly 66 having gears 70, 72 and a
bearing surface 74 configured such that the two gear supports
engage an interior surface of the sidewall 58 and the bearing
support engages an exterior of the sidewall 59. Further, the
sidewall 59 may also have a flange 88 extending from the portion of
the sidewall 59 that is adjacent the housing 24 when the rotational
drive unit 46 is mounted onto the housing 24. By one approach, the
flange 88 may extend from the sidewall 59 toward the rotational
axis of the rotational drive unit 46, as illustrated in FIG. 4. In
the assembly 66, one of the gears 70, 72 is a pinion gear
configured to transmit rotational force to the rotational drive
unit 46 and the other is a rotatable idler gear configured to
support the position of the rotational drive unit 46 without
driving the unit. By another approach, both gears 70, 72 are pinion
gears configured to drive the rotational drive unit 46. In addition
to the gears 70, 72, the support configuration also includes a
bearing surface 74, which may include an arcuate lip 75, as
illustrated in FIG. 14. The bearing surface 74, as shown, has a
surface configured to slidingly support the rotational drive unit
46. In short, the bearing assembly of FIG. 14 has three points of
support for the rotational drive unit 46, one engaging the outside
surface of the rotational drive unit 46 (bearing surface 74) and
two engaging the interior surface of the rotational drive unit 46
(gears 70, 72) via the sun gear 52.
[0055] In another illustrative embodiment, shown in FIG. 15, a
bearing assembly 67 includes a bearing surface 76 and gears 78, 80.
The bearing surface 76 slidingly engages the outer surface of the
rotational drive unit 46, specifically the sidewall 58. Further, in
one embodiment, the sidewall 58 includes an outwardly extending
flange 79 (FIG. 4) that further engages with the bearing surface 76
and extends from the sidewall 58 in a direction away from the
rotational center of the rotational drive unit 46.
[0056] The gears 78, 80 engage the inside of the sun gear 52 on the
inside surface of the rotational drive unit 46. More particularly,
the gear teeth of the sun gear 52 are disposed on the sidewall 58
on an inside surface thereof facing the rotational axis of the
rotational drive unit 46. The gears 78, 80, like gears 70, 72, are
positioned to engage the teeth of the sun gear 52 located on the
interior surface of the sidewall 58 of the rotational drive unit
46. In one illustrative embodiment, the gears are positioned at one
o'clock and eleven o'clock to provide support for the rotational
drive unit and such a configuration provides distributed support
through both gears. Further, either or both of the gears 78, 80 may
be driving gears.
[0057] Yet another example bearing assembly 68 is illustrated in
FIG. 16 and has three gears 82, 84, 86. In this bearing assembly 68
configuration, two gears 82, 84 are positioned inside rotational
drive unit 46 to engage the sun gear 52 and the gear 86 is
positioned to engage the outside surface of the rotational drive
unit. However, if a gear is positioned on the outside of drive unit
46, corresponding gear teeth would be positioned about the outside
circumference of the rotational drive unit 46. To avoid having to
incorporate gear teeth to the outside surface of the drive unit 46,
another approach incorporates three gears engaging the inside
surface of rotational drive unit 46 having sun gear 52 disposed
thereon.
[0058] As incorporated into the movable barrier operator 10, the
three-points of support engage the rotational drive unit 46
including the sun gear 52 along a circumference of the drive unit
46 including both the larger circumference along the sidewall 58
and the smaller circumference along sidewall 59. Thus, the housing
24, which has the bearing assembly with the three-points of
support, is operably connected to the rotational drive unit at the
circumference of the rotational drive unit 46. The circumference
may be on the inner surface, outer surface, or both surfaces of the
rotational drive unit 46. More particularly, as used herein the
circumference may include the inner and outer surfaces of the
sidewall 58, the flange 79, along with the inner and outer surfaces
of the sidewall 59 and the flange 88. By one approach, the sun gear
52 is disposed on an interior surface of the larger circumference
(sidewall 58) of the rotational drive unit 46 such that a driving
or pinion gear is configured to rotate the sun gear 52 and
rotational drive unit 46, while other bearings may support the
rotational drive unit 46 at the circumference such as through
arcuate surfaces or idler gears or at the smaller circumference
(sidewall 59). More specifically, the rotational drive unit 46 may
be supported by at least one driving pinion gear and at least one
support gear, both of which are positioned off-set from a center of
the rotational drive unit 46 and sun gear 52 such that the sun gear
52 and rotational drive unit 46 are not supported by a central
bearing. By another approach, a sliding engagement also supports
the rotational drive unit 46 along with the gears. As mentioned
above, the sliding engagement may include an arcuate lip that can
engage either or both sidewalls 58, 59.
[0059] The three-points of support configured to rotate and engage
the rotational drive unit 46 permit the sun gear to have a
substantially hollow center. The substantially hollow center is
configured to receive portions of the barrier mount such as an axle
to which the movable barrier may be mounted. Further, the
rotational drive unit 46 extends below housing 24, which thereby
exposes the sun gear 52 below the housing 24, which does not
significantly extend below the axle. In addition, this exposure is
in a direction facing away from the movable barrier.
[0060] To prevent injury and increase the safety of the device, a
protection mechanism such as a finger guard may be incorporated
into the movable barrier operator. In one illustrative embodiment,
the protection mechanism is configured to protect fingers from
getting pinched between the sun gear and the operator including the
gears such as the pinion gear. In addition, such a guard may also
protect other items such as jewelry or clothing from getting
inadvertently entangled with the gearing. Further, such a guard may
be movable to provide access to the sun gear 52 and closable to
cover the sun gear 52. When the guard is in the access position,
permitting a user to access the sun gear, the removable portion of
the rotational drive unit may be inserted and removed from the
remainder of the rotational drive unit, as discussed below.
[0061] Turning now to FIGS. 5-7, several embodiments of a
protection mechanism or finger guard are illustrated therein. By
one approach, a finger guard 90 may be configured in a closed,
first position that covers the sun gear 52 and an open, second
position that exposes a portion of the side 50 of the rotational
drive unit 46 that faces the housing 24. As mentioned above, a
central bearing is not required to position the rotational drive
unit 46 about the axle 36. In such a configuration, the rotational
drive unit may extend a distance below the housing 24. By extending
the rotational drive unit 46 beyond the housing 24, a portion of
the sun gear 52 extends beyond the housing 24. When the finger
guard 90 is in the first position, the portion of the sun gear 52
that extends beyond the housing 24 is substantially covered by the
finger guard.
[0062] As illustrated in FIG. 5, the finger guard 90 may include
two c-shaped plates 92. In the closed, first position, the c-shaped
plates 92 follow the annular shape of the rotational drive unit 46.
The closed, first position, which substantially covers the portion
of the sun gear 56 that extends beyond the motor housing 24, is
employed during operation of the operator, once the removable
portion 48 of drive unit 46 is secured. In the open, second
position, the c-shaped plates 92 are spread outwardly, thereby
substantially exposing a portion of the sun gear 52 that extends
beyond the motor housing 24. By one approach, the finger guard 90
may be configured to a locked position and an unlocked position,
wherein the locked position covers the sun gear 52 and the unlocked
position permits access to the opening 49 and the removable portion
48.
[0063] FIG. 5 illustrates the c-shaped plates 92 being configured
in the second position thereby providing access to the opening 49.
FIG. 5 also shows the opening 49 with the removable portion 48
disengaged from the first portion 47 of the rotational drive unit
46. To mate the removable portion 48 with the remainder of the
rotational drive unit 46, the c-shaped plates are configured to be
in the second, open position. As can be seen in FIG. 5, the teeth
of the sun gear 52 are disposed on both the removable portion 48
and the first portion 47 of the rotational drive unit 46. When the
projections 54 of the removable portion 48 are inserted through the
apertures 53, the projections 54 are positioned to engage the
movable barrier and the pinion gear assembly 68 may engage the sun
gear 52 that is disposed on both the removable portion 48 and the
first portion 47 of the rotational drive unit 46. Further, once the
removable portion 48 has been mated with the first portion 47, the
c-shaped plates 92 may be moved to the first, closed position,
illustrated in FIG. 5. Further, the c-shaped plates 92 may have a
clasp or locking mechanism 94. The locking mechanism 94 may include
a lock projection 96 on one of the c-shaped plates 92 that mates
with lock opening on the other of the c-shaped plates 92.
[0064] The c-shaped plates 92 are connected to the housing 24 such
that the plates are movable. For example, the plates 92 may rotate
or slide open to provide access to the sun gear 52 and then rotate
or slide closed to cover the sun gear 52. The c-shaped plates 92
are illustrated in FIG. 14 having the rotational drive unit 46
removed, thereby illustrating the bearing assembly 66 and the
c-shaped protection plates 92. By one approach, c-shaped plates 92
are pivotally connected to housing 24 such that they may pivot with
respect to a connection point to the housing 24. As illustrated in
FIG. 14, in one illustrative embodiment, the c-shaped plates 92 are
pivotally connected to housing 24 at the bearings, specifically at
gears 70, 72.
[0065] Another configuration of the finger guard 90 is illustrated
in FIG. 7 and includes an annular plate 100. The annular plate 100
is constructed as a single piece and corresponds to the annular
shape of the rotational drive unit 46, specifically the portion of
the rotational drive unit 46 that extends beyond the housing 24.
Further, the annular plate 100 connects to the housing 24 through
one connection. By one approach, the annular plate 100 is pivotally
connected to the housing 24. By another approach, the annular plate
100 may be slidably connected to the housing. Like the finger guard
of FIGS. 4-6, the finger guard of FIG. 7 covers a portion of the
sun gear 52 that extends below the housing 24. Further, both of the
finger guards 90 including the finger guard with c-shaped plates 92
and the finger guard with the annular plate 100 (FIGS. 5 and 7) are
positioned in between the housing 24 and the rotational drive unit
46. Thus, when the annular plate 100 is in a locked or closed
position, the sun gear 52 is not openly exposed. FIG. 7 also
illustrates that the removable portion 48 may be mated with the
remainder of the rotational drive unit 46 when the annular plate
100 is in the unlocked or open position.
[0066] The finger guard 90 is configured to protect and cover the
sun gear 52. In addition, having the protection plate(s) or finger
guard 90 movable from the covering position to an open position,
permits the removal or insertion of the removable portion 48 of the
sun gear 52. Thus, by configuring the finger guard 90 in the open
position, the removable portion 48 may be mated with the remainder
of the rotational drive unit 46 and with the movable barrier 20. In
short, during installation of the movable barrier operator 10, the
finger guard 90 is positioned in the open positioned to permit the
projections 54 of the removable portion 48 to pass through the
apertures 53 and to engage the wheel 38 onto which the movable
barrier 20 is mounted. By having the finger guard 90 movable
between two positions, one permitting installation of the removable
portion 48 and one covering sun gear 52 during operation, the
finger guard 90 may be mounted to the operator prior to
installation of the operator 10 onto a previously mounted garage
door.
[0067] Turning now to FIG. 17, a method 200 of installing a
shaft-mounted operator is illustrated. At the beginning, an
installer is provided 202 a motor operably coupled to a drive gear
that is configured to engage an associated sun gear and a motor
housing having an attached finger guard or protection plate(s)
configured to move between a first position substantially covering
a portion of the sun gear that extends beyond the motor housing and
a second position substantially exposing the portion of the sun
gear extending beyond the motor housing. To install movable barrier
operator 10 onto a previously installed movable barrier, the
installer arranges 204 the finger guard or protection plates into
the first position that substantially exposes the portion of the
rotational drive unit and the sun gear that extends below housing
24. Thus, the installer may begin by opening the finger guard such
that the removable portion 48 may be mated to opening 49 of
rotational drive unit 46.
[0068] Once the finger guard is positioned to expose the sun gear
52, then, the motor housing and the associated rotational drive
unit with the removable portion removed may be mounted 206 onto the
axle 36 adjacent the wheel 38 while the removable portion 48 is
removed. To this end, an expandable shaft coupling may be used to
attach a support 60 of the housing 24 to the axle 36. Once the
housing 24 is secured to adjacent the wheel 38, the removable
portion 48 may be mated 208 with the remainder of the rotational
drive unit such that the portion of the sun gear 52 on the
removable portion is mated with the sun gear 52 portion that is
disposed on the rotational drive unit. Further, the removable
portion 48 mates the movable barrier operator 10 to the garage door
via placement of portions of the removable portion 48 around
portions of the wheel 38 to which the door 20 is mounted. To this
end, the projections 54 of the removable portion 48 may be extended
through the apertures 53 that are proximate the opening 49 of the
rotational drive unit 46. As the projections 54 are extended
through the apertures 53, the projections engage portions of the
previously installed movable barrier including spokes 40 of the
wheel 38. After mating the removable portion 48 with the opening 49
of the rotational drive unit 46 via mating projections 54 with
spokes 40, the finger guard 90 is positioned 210 into the first
position substantially covering the portion of the sun gear 52 that
extends beyond housing 24.
[0069] Those skilled in the art will recognize that a wide variety
of modifications, alterations, and combinations can be made with
respect to the above described embodiments without departing from
the scope of the invention, and that such modifications,
alterations, and combinations are to be viewed as being within the
ambit of the inventive concept.
* * * * *